US7576251B2 - Process for the double bond hydroisomerization of butenes - Google Patents

Process for the double bond hydroisomerization of butenes Download PDF

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US7576251B2
US7576251B2 US11/107,649 US10764905A US7576251B2 US 7576251 B2 US7576251 B2 US 7576251B2 US 10764905 A US10764905 A US 10764905A US 7576251 B2 US7576251 B2 US 7576251B2
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stream
butene
metathesis
hydroisomerization
feed
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US20060235253A1 (en
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Robert J. Gartside
Thomas P. Skourlis
Hassan Kaleem
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CB&I Technology Inc
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ABB Lummus Global Inc
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Assigned to ABB LUMMUS GLOBAL INC. reassignment ABB LUMMUS GLOBAL INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KALEEM, HASSAN, GARTSIDE, ROBERT J., SKOURLIS, THOMAS P.
Priority to ARP060101457A priority patent/AR056311A1/es
Priority to CA2603484A priority patent/CA2603484C/en
Priority to AT06784361T priority patent/ATE469872T1/de
Priority to MYPI20061726A priority patent/MY148100A/en
Priority to TW095113541A priority patent/TWI352698B/zh
Priority to JP2008506749A priority patent/JP5385606B2/ja
Priority to KR1020077026620A priority patent/KR101168862B1/ko
Priority to PCT/US2006/014123 priority patent/WO2006132706A2/en
Priority to EP06784361A priority patent/EP1871730B1/en
Priority to DE602006014670T priority patent/DE602006014670D1/de
Priority to MX2007012682A priority patent/MX2007012682A/es
Priority to ZA200708909A priority patent/ZA200708909B/xx
Priority to CN2006800209684A priority patent/CN101198572B/zh
Priority to BRPI0609364-7A priority patent/BRPI0609364B1/pt
Publication of US20060235253A1 publication Critical patent/US20060235253A1/en
Priority to NO20074808A priority patent/NO334936B1/no
Priority to US12/460,253 priority patent/US8025857B2/en
Publication of US7576251B2 publication Critical patent/US7576251B2/en
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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/22—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by isomerisation
    • C07C5/23—Rearrangement of carbon-to-carbon unsaturated bonds
    • C07C5/25—Migration of carbon-to-carbon double bonds
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/22—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by isomerisation
    • C07C5/23—Rearrangement of carbon-to-carbon unsaturated bonds
    • C07C5/25—Migration of carbon-to-carbon double bonds
    • C07C5/2506—Catalytic processes
    • C07C5/2556—Catalytic processes with metals
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C11/00—Aliphatic unsaturated hydrocarbons
    • C07C11/02—Alkenes
    • C07C11/08—Alkenes with four carbon atoms
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/22—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by isomerisation
    • C07C5/23—Rearrangement of carbon-to-carbon unsaturated bonds
    • C07C5/25—Migration of carbon-to-carbon double bonds
    • C07C5/2506—Catalytic processes
    • C07C5/2512—Catalytic processes with metal oxides
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C6/00—Preparation of hydrocarbons from hydrocarbons containing a different number of carbon atoms by redistribution reactions
    • C07C6/02—Metathesis reactions at an unsaturated carbon-to-carbon bond
    • C07C6/04—Metathesis reactions at an unsaturated carbon-to-carbon bond at a carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/04—Purification; Separation; Use of additives by distillation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • the present invention is directed to double bond hydroisomerization of C4 olefins.
  • Double bond isomerization is the movement of the position of the double bond within a molecule without changing the structure of the molecule. This is different from skeletal isomerization where the structure changes (most typically representing the interchange between the iso form and the normal form). Skeletal isomerization proceeds by a completely different mechanism that double bond isomerization. Skeletal isomerization typically occurs using a promoted acidic catalyst.
  • hydroisomerization There are two basic types of double bond isomerization, namely hydroisomerization and non-hydroisomerization.
  • the former uses small quantities of hydrogen over noble metal catalysts (such as Pt or Pd) and occurs at moderate temperatures while the latter is hydrogen free and typically employs basic metal oxide catalysts at higher temperatures.
  • noble metal catalysts such as Pt or Pd
  • Double bond hydroisomerization at moderate temperatures is mostly used to maximize the interior olefin (2-butene for example as opposed to 1-butene) since the thermodynamic equilibrium favors the interior olefin at lower temperatures.
  • This technology is used when there is a reaction that favors the interior olefin over the alpha olefin.
  • Ethylenolysis of 2-butene to make propylene is such a reaction.
  • the ethylenolysis (metathesis) reaction is 2-butene+ethylene ⁇ 2 propylenes. Ethylene and 1-butene do not react. If in a mixture of C4 normal olefins, 2-butene can be maximized, then the reaction to propylene will be maximized.
  • the primary hydrogenation reaction of butadiene plus hydrogen forms 1-butene. It proceeds rapidly over the catalysts (relative rate equivalent to 1000). In the presence of hydrogen, two reactions occur with 1-butene. One is the hydroisomerization to 2-butene (relative rate of 100). This reaction requires the presence of hydrogen to proceed but does not consume hydrogen. The other reaction is hydrogenation to normal butane (relative rate of 10). The final reaction is the hydrogenation of 2-butene directly to normal butane. This is the slowest reaction (relative rate of 1) and essentially can be neglected. Under normal conditions over noble metal catalysts, it is expected that the selectivity of 1-butene conversion will be 90% to 2-butene and 10% to n-butane. The latter represents a loss of olefins and is undesirable.
  • Catalyst is located in the zone with higher concentrations of 2-butene, and hydroisomerization of 2-butene to 1-butene occurs. Residual 2-butene in the bottom may be recycled to the tower. If isobutylene is part of the feed mixture, it will also go overhead with the 1-butene.
  • CD-DeIB catalytic distillation-deisobutyleneizer
  • a CD-DeIB will remove isobutylene overhead while maximizing the flow of 2-butene out the bottoms as the 1-butene is hydroisomerized to form 2-butene.
  • the tower typically contains alternating catalyst and fractionation structures above the feed point, and fractionation structures below the feed point. Usually there are about four catalyst sections in the tower. Hydrogen is added below the feed point in order that it is sufficiently dispersed by the time it reaches the feed point.
  • the CD-DeIB in this service accomplishes two functions. It hydroisomerizes the 1-butene to 2-butene to improve recovery of 2-butene and maximize the production of propylene, and also hydrogenates the small remaining amounts of butadiene after the selective hydrogenation to reduce the content of butadiene, which is a poison for the metathesis catalyst.
  • the isobutane and isobutylene are the most volatile components and tend to go overhead in the tower.
  • the 2-butene and the n-butane are the least volatile and tend to go to the bottom.
  • the 1-butene and butadiene have intermediate volatility and will go up or down depending upon the operation of the tower.
  • the tower If the tower is designed so that the 1-butene goes up, it contacts a catalyst section and is hydroisomerized to 2-butene to the limit of the 1-butene/2-butene equilibrium in the tower.
  • the 2-butene formed from hydroisomerization of the 1-butene tends to move downward and the remaining 1-butene continues to move upward.
  • the fractionation sections of the tower separate the 2-butene from the 1-butene.
  • the butadiene which enters the CD-DeIB is slightly less volatile than the 1-butene. Some of the butadiene moves upward where it is hydrogenated over the catalyst. The primary product of the hydrogenation is 1-butene. However, a portion of the butadiene that moves upward is “fully” hydrogenated to n-butane. This constitutes a loss of n-butenes and thus a loss of feed for a metathesis unit. Some of the butadiene moves downward with the primarily 2-butene product. This butadiene is unreacted since it does not come into contact with catalyst. Butadiene can be present in no more than very low levels in the bottoms if the 2-butene is to be fed to a metathesis unit.
  • U.S. Pat. No. 6,420,619 is directed to a process in which both a “back end” catalytic distillation-hydrogenation unit and a catalytic distillation deisobutylenizer tower are employed. This concept replaces the fixed bed selective hydrogenation units normally associated with ethylene plant fractionation systems. There are typically separate fixed bed units for the C3, C4 and C5 fractions to remove the acetylenics and diolefins to low levels prior to further processing.
  • the system of U.S. Pat. No. 6,420,619 uses a C3 to C6 hydrocarbon feedstock from a steam cracker or FCC unit.
  • catalytic distillation towers are used to hydrogenate acetylenics and diolefins in the stream including butadiene, methyl acetylene and propadiene and produce a propylene product stream.
  • the bottoms of the tower produces a C 4 + stream which is then sent to a fractionation system which includes a debutanizer.
  • the C 4 overhead stream from the debutanizer is routed to a CD-DeIB where hydroisomerization occurs.
  • An alternative to a CD-DeIB for obtaining a 2-butene feed steam is a system which employs a fixed bed hydroisomerization unit downstream from a selective hydrogenation unit.
  • the selective hydrogenation unit first removes butadiene to low levels.
  • the effluent C4 feed stream is fed to a second fixed bed reactor and hydrogen is introduced.
  • the 1-butene in the stream hydroisomerizes to 2-butene and the small amount of butadiene that remains reacts.
  • the effluent then goes to a conventional fractionating tower where the isobutylene and isobutane are separated overhead and the 2-butene goes out the bottom where it enters a disengaging drum in which any excess hydrogen is vented.
  • the remainder of the bottoms is used as feed for the metathesis unit.
  • This process requires less catalyst than the CD-DeIB unit because of higher driving forces for the fixed bed.
  • the fractionating tower can be designed to allow more isobutylene to pass into the bottoms effluent, thus saving on utilities and capital since a smaller tower can be used.
  • the disadvantage of the fixed bed system is that the quantity of n-butenes recovered is slightly lower than when a CD-DeIB is used.
  • U.S. Pat. No. 6,686,510 is directed to the production of high-purity isobutylene and propylene from hydrocarbon fractions having four carbon atoms.
  • the process disclosed in this document comprises three successive stages, namely 1) the selective hydrogenation of butadiene with isomerization of 1-butene into 2-butene up to thermodynamic equilibrium; 2) the separation by distillation into a top fraction containing isobutylene and a bottom fraction containing 2-butene and butane, and 3) the metathesis of the 2-butene fraction with ethylene to produce propylene.
  • a double bond hydroisomerization process for increasing the selectivity of 2-butene over 1-butene is provided.
  • the process increases the yield of 2-butenes from a given C4 feed stream and produces a 2-butene stream containing a lower concentration of butadiene, thereby resulting in less fouling of the downstream catalyst during a subsequent process such as metathesis.
  • the invention in a preferred form is a process for the preferential conversion to 2-butene of a C4 stream containing 1-butene and 2-butene, comprising mixing the C4 stream with a first hydrogen stream to form a feed stream, hydroisomerizing the feed stream in the presence of a first hydroisomerization catalyst in order to convert at least a portion of the 1-butene to 2-butene, thereby producing a hydroisomerization effluent, passing the hydroisomerization effluent through a fractionation column to form a top stream comprising isobutane and isobutylene and a bottoms stream comprising 2-butene, withdrawing a recycle stream from the fractionation column at a location above the feed point at which the weight ratio of 1-butene to 2-butene is high, and combining the recycle stream with at least one of the C4 stream and the feed stream upstream from the hydroisomerization catalyst. Withdrawal preferably takes place at an elevation in the column at which the 1-butene concentration would
  • the feed stream further comprises butadiene
  • the method further comprises hydrogenating the feed stream upstream from the hydroisomerization reactor to reduce the butadiene content of the C4 stream to no more than about 1 wt %.
  • the recycle stream preferably is mixed with the feed stream after the feed stream has been hydrogenated.
  • the process further comprises mixing the bottoms stream with a suitable metathesis reactant to form a metathesis feed stream, and feeding the metathesis feed stream to a metathesis reactor and reacting the 2-butene with the metathesis reactant to form a metathesis product.
  • a suitable metathesis reactant comprises ethylene
  • the metathesis product comprises propylene.
  • the feed stream further includes C5 and/or heavier components
  • the method further comprises removing the C5 and/or heavier components from the hydroisomerization effluent prior to fractionation.
  • the bottoms stream or the metathesis feed stream is purified before the metathesis feed stream is sent to the metathesis reactor.
  • a second hydrogen stream is fed to the hydroisomerization reactor at a location downstream from the feed point of the first hydrogen stream.
  • a third hydrogen stream is fed to the fractionation column at a location downstream from the feed point of the second hydrogen stream.
  • One, two or all three of the hydrogen streams optionally may further comprise carbon monoxide.
  • the method further comprises the step of separating the metathesis product from heavier components to form a heavy component stream and combining the heavy component stream with the hydroisomerization effluent.
  • the top stream and the bottoms stream each contain small quantities of 1-butene.
  • the flow rate of 1-butene in the top stream is greater than the flow rate of 1-butene in the bottoms stream.
  • the flow rate of 1-butene in the bottoms stream is greater than the flow rate of 1-butene in the top stream.
  • the hydroisomerization catalyst in the fixed bed hydroisomerization reactor frequently comprises a group VIII metal on a support. An additive of gold, silver, and/or alkali metals also can be included.
  • the apparatus comprises a hydroisomerization reactor configured to contain a hydroisomerization catalyst for converting at least a portion of the 1-butene in the feed stream to 2-butene, a fractionation column for separating the hydroisomerized feed stream into a top stream comprising isobutane and isobutylene, and a bottoms stream comprising 2-butene, a side draw near the top of the fractionation column for removing a recycle stream, and a recycle inlet for combining the recycle stream with the feed stream upstream from the hydroisomerization catalyst.
  • the invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others and the apparatus possessing the features, properties and relation of elements exemplified in the following detailed disclosure.
  • FIG. 1 is a schematic drawing of a first embodiment in which a 2-butene stream is produced.
  • FIG. 2 is a schematic drawing of a second embodiment in which a 2-butene stream is produced, with C5+ compounds being removed prior to fractionation of the C4 compounds.
  • FIG. 3 is a schematic drawing of an embodiment in which a 2-butene stream is produced and used as the feed stream in a metathesis reaction.
  • FIG. 4 is a schematic drawing of another embodiment in which a 2-butene stream is produced and used as the feed stream in a metathesis reaction.
  • FIG. 5 is a graph showing conversion and selectivity profiles for the hydroisomerization of 1-butene to 2-butene.
  • FIG. 6 is a graph showing the ratio of 1-butenes to 2-butenes in a deisobutylenizer tower which is downstream from a fixed bed reactor.
  • FIG. 7 is a graph showing the driving force at various stages in a deisobutylenizer tower which does not have a side draw for removal of 2-butenes near the top of the column.
  • FIG. 8 is a graph showing the 1-butene content at various stages of a deisobutylenizer tower when there is no side draw from the top of the column and when side draws of various flow rates are employed.
  • the invention provides an apparatus and method for obtaining improved yields of 2-butene from a C4 stream as compared to prior known techniques.
  • a fixed bed hydroisomerization reactor is used in conjunction with a deisobutylenizer tower.
  • a side draw is removed from the tower at a location at which the driving force for the hydroisomerization reaction to 2-butene is high and this side draw is recycled to the fixed bed hydroisomerization reactor.
  • FIG. 1 an apparatus and process are shown for producing a 2-butene stream from a C4 stream.
  • the C4 stream contains 1-butene and 2-butene, and typically also contains butadiene and butane. This stream often also contains some C5 and higher molecular weight materials.
  • the overall process is designated as 10 .
  • a C4 stream, which is designated as 12 is combined with a recycle stream 18 to form stream 20 , which is fed to a fixed bed hydroisomerization reactor 22 .
  • a typical C4 feed stream to the hydroisomerization reactor 22 contains 2-50 parts by weight 1-butene, 2-50 parts by weight 2-butene, 2-50 parts by weight isobutylene, 2-50 parts by weight isobutane, 2-50 parts by weight n-butane and 0-1 part by weight butadiene, the total parts by weight being 100. In many cases, butadiene is no more than 1500 ppmw.
  • Hydrogen in stream 16 is fed directly to the hydroisomerization reactor 22 or is combined with streams 12 and 18 to form stream 20 .
  • 1-butene is hydroisomerized into 2-butene.
  • Typical reactor pressures are 2-30 barg, and usually 5-18 barg.
  • Typical reactor inlet temperatures are 80-250 Deg. F. and usually 120-180 Deg. F. Hydrogen and other non-condensibles are vented from the reactor effluent stream 24 in stream 25 . Any suitable hydroisomerization catalyst can be used. Examples of such catalysts are noble metals (ca. Pd) supported on alumina. Additives to the metals including Ag, Au, etc can be used to modify the reaction characteristics.
  • the remainder of the reactor effluent, in stream 26 is fed to a deisobutylenizer tower 36 .
  • Typical tower temperatures are 80-220 Deg. F. and usually 100-160 Deg. F.
  • Typical reactor pressures are 2-12 barg and usually 3-8 barg.
  • the top stream 38 from the deisobutylenizer tower 36 contains isobutylene and isobutane. Small quantities of 1-butene and 2-butene typically are included in the top stream 38 .
  • the bottoms stream 40 contains most of the 2-butene.
  • a portion of the liquid is removed from the upper end 37 of the column in an upper side draw 39 .
  • the side draw 39 preferably constitutes the recycle stream 18 , which is combined with feed stream 12 as is indicated above, thereby providing for additional conversion of the 1-butene present in stream 18 in the hydroisomerization reactor 22 .
  • the embodiment of FIG. 1 uses significantly less catalyst than a conventional CD-DeIB process.
  • the embodiment of FIG. 1 converts more of the 1-butene originating in the C4 feed stream 12 into 2-butene as compared to a conventional system employing a fixed bed and fractionating tower in which no a side draw is used.
  • the side draw 39 preferably is positioned at the elevation in deisobutylenizer tower 36 at which the 1-butene concentration would be the highest if no side draw were included. Typically, this is near the top of the column.
  • the point of maximum driving force for the hydroisomerization reaction is determined at the conditions under which the column is set to operate.
  • the reaction between 1-butene and 2-butene can be represented by equation (1) where B1 is 1-butene, B2 is 2 butene, k b1 is the reaction k for B1 to B2 and k b2 is the reaction k for B2 to B1.
  • the rate of reaction is the reaction k times the concentration of the reactant.
  • the ratio of the reaction k's, the equilibrium coefficient K eq is equal to the ratio of k b1 to k b2 .
  • This driving force factor can be plotted as a function of position in the tower for a particular system and is the preferred technique for locating the optimal point for the side draw location.
  • FIG. 2 another embodiment is shown for producing a 2-butene stream from a C4 feed stream in which a side draw is removed from a deisobutylenizer tower.
  • any C5+ compounds in the feed or heavier sulfur compounds in the feed are removed upstream from the deisobutylenizer tower.
  • the production of butanes during the hydroisomerization reaction is minimized by the use of multiple hydrogen feed streams and/or the inclusion of small quantities of carbon monoxide in one or more of the hydrogen streams.
  • the inventors have surprisingly found that CO acts as an inhibitor for the hydrogenation reactions of butenes to butanes while allowing the double bond hydroisomerization reactions to continue.
  • Carbon monoxide optionally is included with the hydrogen in stream 116 .
  • Hydrogen and/or carbon monoxide optionally also can be injected into the reactor 122 at a second location approximately midway along the length of the reactor 122 in stream 121 .
  • 1-butene is hydroisomerized into 2-butene, forming reactor effluent stream 124 .
  • Hydrogen and other non-condensibles are vented from the reactor effluent stream 124 in stream 125 .
  • the remaining reactor effluent in stream 126 is fed to a first fractionating tower 130 .
  • C4 compounds are removed from the top in stream 132 and C5+ compounds are removed as bottoms in stream 134 .
  • a hydrogenation catalyst bed 131 also known as a “guard bed”, hydrogenates remaining butadienes to form butenes.
  • Stream 132 is subsequently fed to a deisobutylenizer tower 136 .
  • the top stream 138 from the deisobutylenizer tower 136 contains isobutylene and isobutane, and small quantities of 1-butene and 2-butene.
  • the bottoms stream 140 contains most of the 2-butene.
  • At the upper end 137 of the deisobutylenizer tower 136 there is an elevation at which the concentrations of 1-butene is at a maximum if no side draw is used.
  • An upper side draw 139 is positioned at this elevation.
  • the side draw 139 forms the liquid recycle stream 118 which is combined with feed stream 112 as is indicated above.
  • the location of the side draw 139 preferably is selected in the same manner as in the embodiment of FIG. 1 , i.e. the elevation at which the ratio of 1-butene to 2-butene is at a maximum if no side draw is taken.
  • FIG. 3 depicts a system 210 for producing propylene from a C4 stream 212 .
  • the C4 stream 212 is combined with a recycle stream 218 to form stream 220 , which is fed to a fixed bed hydroisomerization reactor 222 .
  • Hydrogen in stream 216 is combined with streams 212 and 218 to form stream 220 or can be fed directly to the reactor 222 .
  • Carbon monoxide optionally is included with the hydrogen in stream 216 .
  • Hydrogen and optionally also carbon monoxide can be injected into the reactor 222 at a second location approximately one third of the way along the length of the reactor 222 in stream 221 and at a third location about two thirds of the way along the length of the reactor 222 in stream 223 .
  • the volume of the hydrogen and optional carbon monoxide introduced in stream 216 is reduced in order that the overall volume of hydrogen and CO is no more than is necessary to achieve the desired result.
  • the advantage of splitting the hydrogen into three different feed points is to reduce the production of butanes in the reactor 222 .
  • the advantage of including carbon monoxide in streams 216 , 221 and/or 223 is to inhibit hydrogenation reactions while allowing hydroisomerization reactions to proceed.
  • the CO and H2 preferably are injected at a single point upstream from the hydroisomerization reactor.
  • the CO to H2 ratio is between 0.1% and 3 % on a molar basis, more preferably 0.1-0.5%, and is typically 0.2-0.4% on a molar basis.
  • hydrogen preferably is apportioned at each feed point in a manner such that the total volume of the catalyst in the hydroisomerization reactor is in an active state.
  • the ratio of CO to H2 at each point of injection preferably, but not necessarily, is the same as at the other points of injection. It is also feasible to have one of the streams contain only hydrogen.
  • 1-butene is hydroisomerized into 2-butene.
  • the reactor effluent stream 224 is vented to remove hydrogen and other non-condensibles in stream 225 and is then combined with a metathesis recycle stream 227 to form stream 226 , which is fed to a deisobutylenizer tower 236 .
  • a deisobutylenizer tower 236 Above the feed point in deisobutylenizer tower 236 , at the upper end 237 of the deisobutylenizer tower, there is an elevation at which the concentrations of 1-butene is at a maximum if no side draw is included.
  • An upper side draw 239 is positioned at this location, forming recycle stream 218 .
  • Recycle stream 218 is combined with feed stream 212 and enters the hydroisomerization reactor 222 as is indicated above.
  • the top stream 238 from the deisobutylenizer tower 236 contains isobutylene and isobutane, and small quantities of 1-butene and 2-butene.
  • the bottoms stream 240 contains most of the 2-butene.
  • the butadiene content of stream 240 is less than 50 parts per million based on weight, and more preferably less than 10 parts per million based on weight, since butadiene is a poison for metathesis catalysts.
  • Stream 240 optionally is purified in one or more guard beds 243 .
  • An ethylene feed stream 242 is combined with the bottoms stream 240 to form a metathesis reactor feed stream 244 . This stream enters the metathesis reactor 246 , in which the 2-butene and ethylene react to form a metathesis product stream 248 .
  • the metathesis product stream 248 contains propylene, butenes and C5+ hydrocarbons.
  • the propylene is separated from the heavier hydrocarbons in separator 250 and is removed as the product in stream 252 .
  • the C4, C5 and heavier hydrocarbons are recycled in metathesis recycle stream 227 and are combined with stream 224 to form stream 226 .
  • FIG. 4 depicts a system 310 for producing propylene from a C4 stream.
  • a C4 feed stream 312 is passed though a selective hydrogenation unit 313 which hydrogenates butadiene, producing a low-butadiene C4 feed stream 314 .
  • a hydrogen stream 316 and a recycle stream 318 are combined with stream 314 to form stream 320 .
  • Stream 320 is fed to a fixed bed hydroisomerization reactor 322 in which 1-butene is hydroisomerized into 2-butene.
  • the split feed of hydrogen to the hydroisomerization reactor and the inclusion of carbon monoxide with the hydrogen can be used in this embodiment, as well as any of the embodiments of FIGS. 1-4 .
  • the reactor effluent stream 324 is vented to remove hydrogen and other non-condensibles in stream 325 and the remainder is combined with a metathesis recycle stream 327 to form stream 326 , which is fed to a fractionating tower 330 .
  • C4 compounds are removed from the top in stream 332 and C5+ compounds are removed as bottoms in stream 334 .
  • a hydrogenation catalyst bed 331 also known as a “guard bed”, hydrogenates remaining butadienes to form butenes.
  • Stream 332 is subsequently fed to a deisobutylenizer tower 336 .
  • a deisobutylenizer tower 336 Above the feed point in deisobutylenizer tower 336 , at the upper end 337 of the deisobutylenizer tower 336 , proximate or at the location at which the concentrations of 1-butene and butadiene are at a maximum, an upper side draw 339 is positioned, the side draw 339 forming recycle stream 318 .
  • Recycle stream 318 is combined with feed stream 312 and enters the hydroisomerization reactor 322 .
  • the top stream 338 from the deisobutylenizer tower 336 contains isobutylene and isobutane, and small quantities of 1-butene and 2-butene.
  • the bottoms stream 340 contains the 2-butene.
  • Stream 340 optionally is purified in one or more guard beds 343 .
  • An ethylene feed stream 342 is combined with the bottoms stream 340 to form a metathesis reactor feed stream 344 .
  • This stream enters the metathesis reactor 346 , in which the 2-butene and ethylene react to form a metathesis product stream 348 .
  • the metathesis product stream 348 contains propylene, butenes and C5+ hydrocarbons.
  • the propylene is separated from the heavier hydrocarbons in separator 350 and is removed as the product in stream 352 .
  • the C4, C5 and heavier hydrocarbons are recycled in stream 327 and are combined with the debutanizer feed from stream 324 (usually after venting) in stream 326 .
  • the removal of a side draw and recycling of the side draw back to the hydroisomerization reactor provides several processing advantages.
  • the invention is particularly useful for processing stream cracker C4 streams and refinery C4 streams.
  • steam cracker C4 streams contain appreciable quantities of butadiene and therefore require inclusion of a selective hydrogenation unit to convert butadiene to butenes.
  • Refinery C4 streams have a low butadiene content that can be processed within the hydroisomerization unit, and thus inclusion of a selective hydrogenation unit is not required.
  • the inclusion of a fractionator upstream from the deisobutylenizer tower provides for the removal of heavy materials that enter the system along with the C4s.
  • Refinery C4 streams often contain heavier sulfur compounds including dimethyl disulfide (DMDS) and diethyl disulfide (DEDS), both of which can be removed by a first fractionating tower, as is shown in FIGS. 2 and 4 .
  • DMDS dimethyl disulfide
  • DEDS diethyl disulfide
  • the examples show various processing options for a single C4 feed stream having the composition shown below on Table 1. While any type of C4 stream can be used in the invention, such streams typically are generated from a steam cracker C4 stream, a C4 stream from an FCC unit, or a mixture of the two.
  • the methane is soluble methane from an upstream selective hydrogenation unit where the butadiene has been reduced from approximately 45,000 ppmw in the feed to 1300 ppmw in the effluent.
  • the hydrogen for that reaction contains some quantities of methane.
  • the total 2-butenes are 26.63 wt % and the 1-butene is 11.63 wt %.
  • the hydrogen used in the examples consists of a mixture of 95 wt. % hydrogen and 5 wt. % methane, with a molecular weight of 2.11.
  • the 1-butene is reacted to form 2-butene and the remaining butadiene is hydrogenated to 1-butene.
  • the selectivity is defined as that portion of the 1-butene converted that is converted to n-butane.
  • the equilibrium mixture of 1-butene and 2-butene would result in the conversion of 84.9% of the 1-butene. Note that complete conversion can not be obtained in a single step due to the limitation of equilibrium.
  • FIG. 5 shows the conversion/selectivity for reaction of the C4 stream over a hydroisomerization reactor containing a supported Pd catalyst.
  • FIG. 5 shows the performance when using a single pure hydrogen feed and the improvement which can result from the use of small quantities of CO with hydrogen injected at multiple feed points in the hydroisomerization reactor.
  • the conversion to 1-butene is 65% with a selectivity to n-butene of 6.7%.
  • Selectivity to butane is defined as the total butane produced divided by the 1-butene converted.
  • the location preferably is the point of maximum driving force for the hydroisomerization reaction. This location is defined by considering the composition profiles of the tower using a fixed bed only (no side draw). The composition profile over the tower for Example 2 with a side draw of 0 is shown in FIG. 6 .
  • FIG. 6 shows the ratio of 2-butene to 1-butene. As can be seen, for most of the tower, the ratio is below equilibrium indicating potential favorable reaction of 1-butene to 2-butene.
  • FIG. 7 shows the “driving force” as defined above.
  • the potential locations for removal of a side draw are between stages 9 and 29 with the optimal location at stage 18 .
  • This location will vary depending upon the specifics of the feedstock and fractionation operating conditions. It is however desired that the location be at or near the point of optimal driving force with preferred locations having driving forces at least 85% of the maximum, and usually at least 90% of the maximum, as defined by the composition profile without side draw.
  • FIG. 8 shows the impact of the side draw rate on the 1-butene composition in the fractionation column. A larger side draw results in a lower 1-butene concentration at the top of the column.
  • the second tower, Tower 1B consisted of 129 equilibrium stages and had a reflux ratio of 4.5 (reflux to feed). The additional 35 stages helped to achieve better separation.
  • This tower also contained 23581 lb of catalyst in 2042 ft 3 of structures. The balance of the tower was filled with high efficiency fractionation packing. Hydrogen was added to supply the required hydrogenation of butadiene and 1-butene hydroisomerization.
  • the third tower, designated as Tower 1C consisted of 94 equilibrium stages and operated at a reflux ratio of 6.20 (reflux to feed).
  • This tower also contained 23581 lb of catalyst in 2042 ft 3 of structures. The balance of the tower was filled with high efficiency fractionation packing. Hydrogen was added to supply the required hydrogenation of butadiene and 1-butene hydroisomerization.
  • the feedstock is as shown in Table 1.
  • Table 1 There is a considerable amount of 1-butene and butadiene in the feed. It is the objective of the design to produce a bottoms stream containing a high fraction of 2-butene and minimal amount of butadiene.
  • the 1-butene tends to rise in the tower and the butadiene tends to move lower. This impacts the performance of the tower in that fractionation conditions must be varied to achieve a mixture with low butadiene.
  • Tower 1C used reflux to improve fractionation performance. In this case, a higher reflux ratio (6.2 versus 4.5) was used. This improved the recovery to 93.8%. However, this option required more capital cost due to the higher traffic in the tower needed a larger tower diameter. Further, the energy requirement was greater due to the higher reboiler and condenser duties.
  • Example 2A a side draw was removed from the fractionation tower at stage 18 in an amount of 10,000 (Example 2A) or 20,000 lb/hr (Examples 2B-2C).
  • Examples 2B-2C The results are shown on Table 3.
  • a side draw of 10,000 lb/hr resulted in an increase in the amount of n-butene recovery (including 2-butene) in the bottoms from 90.33% to 93.87%. This is a result of the higher 1-butene conversion made possible by the recycle of the side draw.
  • a side draw of 20,000 lb/hr resulted in a n-butene recovery in the bottoms of 96.73% (Example 2B).
  • the isobutylene content in the bottoms was also relatively high at 17.87%.
  • the difference is the amount of distillate product that is taken.
  • the % of the n-butene feed in the bottoms was 92.55% (Example 2C).
  • the distillate product (overhead) rate controls the amount of isobutylene and butadiene that is in the bottoms product.
  • a higher distillate product flow can be taken, more stages can be employed, or more reflux can be used. All are commercially useful options.
  • the fractionation tower was assumed to remain the same at 94 theoretical stages and a fixed reflux ratio of 4.5. It is important to note that in all cases, the butadiene is lower than that obtained under similar conditions for the CD-DeIB. This is the result of the butadiene conversion in the hydroisomerization reactor upstream of the fractionating tower.
  • Comparative Example 2 The procedure of Comparative Example 2 was repeated with the exceptions that a combined feed of hydrogen and CO was added at two different locations along the length of the hydroisomerization reactor, and the simulated reactor was a fixed bed with 5.4% 1-butene saturation.
  • Example 3 The procedure of Example 3 was repeated with the exception that a side draw was added at stage 18 in an amount of 10,000 lb/hr. This side draw was mixed with the C4 feed stream and re-injected into the hydroisomerization reactor. Use of the side draw increased the % recovery of n-butenes in the bottoms from 93.82% (Example 3) to 96.21% (Example 3A).
  • Example 3A The procedure of Example 3A was repeated with the exception that the side draw at stage 18 was increased to an amount of 20,000 lb/hr. This side draw was mixed with C4 feed stream and re-injected into the hydroisomerization reactor. Use of the increased side draw increased the % recovery of n-butenes in the bottoms from 96.21% (Example 3A) to 97.72% (Example 3B). Note that under identical tower operating specifications (Examples 3, 3A, and 3B), Example 3B resulted in an increase in isobutylene in the bottoms increasing to over 17%. In some cases this is undesirable for downstream processing.
  • Example 3B The procedure of Example 3B was repeated with the exceptions that a side draw was added at stage 18 in an amount of 20,000 lb/hr and the tower was adjusted to have a 2.85 wt % isobutylene content in the bottoms.
  • the side draw was mixed with the C4 feed stream and re-injected into the hydroisomerization reactor.
  • the use of the side draw increased the % recovery of n-butenes in the bottoms from 93.82% (Example 3A) to 95.08% (Example 3C). Note however, by increasing the overhead product flow to recover more isobutylene overhead, the net recovery of n-butenes in the bottoms product dropped from 97.72% to 95.08%.
  • Table 4 The results are shown on Table 4.

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US11/107,649 US7576251B2 (en) 2005-04-15 2005-04-15 Process for the double bond hydroisomerization of butenes
ARP060101457A AR056311A1 (es) 2005-04-15 2006-04-12 Proceso para la hidroisomerizacion del doble enlace de butenos
DE602006014670T DE602006014670D1 (de) 2005-04-15 2006-04-14 Verfahren zur doppelbindungs-hydroisomerisierung von butenen
CN2006800209684A CN101198572B (zh) 2005-04-15 2006-04-14 丁烯的双键加氢异构化方法
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JP2008506749A JP5385606B2 (ja) 2005-04-15 2006-04-14 ブテンの二重結合ヒドロ異性化法
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EP06784361A EP1871730B1 (en) 2005-04-15 2006-04-14 Process for the double bond hydroisomerization of butenes
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US12/460,253 US8025857B2 (en) 2005-04-15 2009-07-16 Apparatus for the double bond hydroisomerization of butenes
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KR101168862B1 (ko) 2012-07-30
JP2008538555A (ja) 2008-10-30
AR099706A2 (es) 2016-08-10
KR20080007370A (ko) 2008-01-18
US8025857B2 (en) 2011-09-27
CA2603484C (en) 2014-02-11
BRPI0609364B1 (pt) 2015-08-04
NO20074808L (no) 2007-12-04
EP1871730A2 (en) 2008-01-02
CN101198572B (zh) 2013-07-24
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ATE469872T1 (de) 2010-06-15
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CN101198572A (zh) 2008-06-11
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MX2007012682A (es) 2008-01-11
NO334936B1 (no) 2014-07-21
AR056311A1 (es) 2007-10-03
EP1871730B1 (en) 2010-06-02
BRPI0609364A2 (pt) 2010-03-30
US20090280041A1 (en) 2009-11-12
US20060235253A1 (en) 2006-10-19

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